PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

PETROLEUM ENGINEERING
SUMMER COURSE
2015

Petroleum Engineering Design

PART A

Drilling Engineering

CHAPTER 3

Mud Hydraulics

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Content

Fluid Dynamic Behaviour

Rheological Models
Flow Regimes
Bingham Model Pressure Losses
Power Law Model Pressure Losses
Bit Pressure Losses and Hydraulic OpAmizaAon

Fluid Dynamics Behaviour

The Moving Fluid

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

HydrostaAc Pressure
Field units

p = 0.052 h
[ psi ] = 0.052 [ ppg ] [ ft ]
SI Units

p = g h
[ Pa ] = [ kg / m3 ] 9.81 [m]

Concept of ECD
Hydrostatic Fluid Column
Friction Pressure Losses in the Annulus

!"#!(!!") =

!!"# ! !"# + !!""#$#% (!"#)

!
0.052!"#!(!")

!!"# ! !!" + !!""#$#% (!!" !"#$%&')

!
0.052!!!"#!(!!")

!"#!(!"#) =

!!"# ! !"# + !!""#$#% (!"#$%)

!
0.052!!!"#!(!"#)

Chair of Drilling Engineering - University Leoben

ECD (Shoe)

TVD (Bit)

!"#!(!!") =

TVD (Shoe)

Consider Fluid Static and Dynamic

Behaviour

ECD (Bit)

PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

System Pressure Losses

pStdPipe = pSurfEquip + pDrillString + pMWD/Motor + pBit + pAnnulus
pStdPipe = p parasitic + pbit

Assump7on: minimum
annular velocity = 120
A/min

Surface Equipment
Standpipe
Kelly Hose
Swivel
Kelly
Drill String
Pipe
Collars
BHA
Motor/MWD
Bit Nozzles
Annulus

Pressure Loss in Wellbore SecAons

Section 1: Surface Lines
Section 2: Inside Drillpipes
Section 7: Annulus Drillpipes, Cased Hole
Section 6: Annulus Drillpipes, Open Hole
Section 3: Inside Drill Collars
Section 5: Annulus Drill Collars, Open Hole
Section 4: Bit Nozzles

p = ps + pDP + pDC + pADC + pADP + pbit

p = p parasitic + pbit

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Surface Lines Pressure Loss

Case

Stand Pipe

Hose

Swivel

Kelly

Length

ID

Length

ID

Length

ID

Length

ID

(Ft.)

(In.)

(Ft.)

(In.)

(Ft.)

(In.)

(Ft.)

(In.)

1
2
3
4

40

3.0

45

2.0

2.0

40

2.25

40

3.5

55

2.5

2.5

40

3.00

45

4.0

55

3.0

2.5

40

3.25

45

4.0

55

3.0

3.0

40

4.0

E Value

Surf.
Eq.

Imperial Units

Metric Units

2.5x10-4

8.8x10-6

9.6x10-5

3.3x10-6

5.3x10-5

1.8x10-6

4.2x10-5

1.4x10-6

ps = E m0.8q1.8 p0.2

[ psi]

Ref: Oilwell Drilling Engineering, Rabia, ISBN 0-86010-714-0

Rheological Models
From Water to Mud

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Measurement of Rheology
Funnel
Fann viscometer
Describing shear rate/shear stress behaviour of
the uid
Try to get enough measurements to describe
behaviour (high and low shear rates)

Basic Laboratory Measurements

Several types of equipment are
used for the measurement of a
mud's ow properAes. Not all are
capable of giving informaAon that
is useful in predicAng circulaAng
pressure losses and other items
required in the design of a
hydraulics program.

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

RotaAonal Viscometer
Newtonian Fluids:

= 300

[cp]

Bingham Fluids:

p = 600 300

[cp]

YP = y = 300 p #$lb /100 ft 2 %&

Power Law Fluids:

n = 3.32 log
K=

600
300

510 300
511n

Ref: Oilwell Drilling Engineering, Rabia, ISBN 0-86010-714-0

Non-Newtonian Fluids
One Parameter
Newtonian

Two Parameters
Bingham, Power-Law

Three Parameters
Modied Power Law

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Newtonian Model

Shear stress,

increasing temperature

= !!
Shear rate,

where:
= viscosity

Time Independent Behavior of Non-

Newtonian Fluids

Ref: www.drillcompfluids.com

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Time Dependent Behavior of

Non-Newtonian Fluids

Ref: www.svce.ac.in

Shear stress,

Bingham PlasAc Model

pe
Slo

Yield Point

c
las7
= p

ty
osi
visc

= !! + ! !

True Yield Stress

Shear rate,

where:
p = plasAc viscosity
y = yield point

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Power Law Model

Many non-Newtonian uids, parAcularly
many polymer muds are best characterized
by the Power Law:

Shear stress,

n=0.2

! = !! !
where:
n = ow behavior index, between 0 and 1 K =
consistency index

n=0.5

n=0.7
n=1

Log Shear stress,

Shear rate,

Ref: Oilwell Drilling Engineering,

Rabia, ISBN 0-86010-714-0

Log Shear rate,

Shear stress,

Modied Power Law Model

! = !!! + !! ! !
Shear rate,

where:
n = ow behavior index, between 0 and 1 K =
consistency index
0 = yield point

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Flow Regimes
From Laminar to Turbulent

AssumpAons

Drill string is placed concentric in the casing or hole

No drill string rotaAon
Open hole is circular and of known diameter
Drilling uid is incompressible
Flow is isothermal

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Laminar Flow
Model of uid moving in dened layers
Fluid velocity is zero at the wall
r

r
r2

r2
v

(a)

r1

(b)
Velocity prole for laminar ow a) Pipe ow b) Annular ow

Turbulent Flow
Fluid lamina becomes unstable
ChaoAc diused ow pagern
Experimental data has been used to develop
empirical correlaAons
TransiAon from laminar to turbulent dened by
dimensionless groups

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

TransiAon Flow
TransiAon from laminar to turbulent

Pipe And Annular Flow

Pipe Flow
Pipe ow equaAons use inner diameter of pipe

Annular Flow
Extension of the pipe ow equaAons
Slot approximaAon
Hydraulic
RaAo cross-secAonal area to weged perimeter, 4 Ames to give
hydraulic diameter

de = douter dinner

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Reynolds Number - Pipes

Used to dene the transiAon from laminar to turbulent

Is compared with a criAcal Reynolds Number
If NRe < NRec => laminar, else turbulent (neglecAng transiAon)
Characterizing forces of inerAa and viscous forces
Reynolds Number
Annulus

SI Units

Imperial Units
Newtonian and
Bingham

v d
N Re =

Newtonian and Bingham

Power Law

CriAcal Reynolds Number

Newtonian Model: NRec = 2100

Bingham Model:
NRec from
Hedstrom
Number, NHe

Pipe

Power Law Model:

ApproximaAon ajer Leitao et al.

Chair of Drilling Engineering - University Leoben

Annulus

! < 0.2 !!"# = 4200

0.2 ! 0.45 !!"# = 5960 8800!!
! > 0.45 !!"# = 2000

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Stanton Chart and Fanning FricAon

Factor for Circular Pipes

Step by Step Pressure Loss

CalculaAons for Pipe and Annular
Flow
Bingham Model
Compare Laminar and Turbulent
Results and Use the Larger One as
EecAve Pressure Loss

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Step 1: Bingham Rheological

Behaviour
PlasAc viscosity

Yield Point

Step 2: Bingham Full Pipe

Pressure Losses
Laminar:

Turbulent:

Does not need

fricAon factor
calculaAon!

Calculate both, laminar and turbulent pressure losses and

select the larger of the two values as eecAve pressure loss in
the secAon.

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Step 3: Bingham Annular

Pressure Losses
Laminar:

!!!
!! !
=
!"
1000 !! !!

Turbulent:

!!
200 !! !!

Does not need

fricAon factor
calculaAon!

Calculate both, laminar and turbulent pressure losses and

select the larger of the two values as eecAve pressure loss in
the secAon.

Step by Step Pressure Loss

CalculaAons for Pipe and Annular
Flow
Power Law Model
Compare Laminar and Turbulent
Results and Use the Larger One as
EecAve Pressure Loss

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Step 1: Power Law Rheological

Behaviour
Flow index

n = 3.32 log

Consistency index

K=

600
300

510 300
511n

Step 2: Power Law Reynolds Numbers

Full Pipe:

Annulus:

d = inside diameter of pipe

d1 = inside diameter of annulus
d2 = outside diameter of annulus

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Step 3: Power Law FricAon Factor

from Colebrooke Diagram

AlternaAvely:

Step 4: Power Law Full Pipe

Pressure Losses
Laminar:

Turbulent:

Calculate both, laminar and turbulent pressure losses and

select the larger of the two values as eecAve pressure loss in
the secAon.

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Step 5: Power Law Annular

Pressure Losses
Laminar:

Turbulent:

Calculate both, laminar and turbulent pressure losses and

select the larger of the two values as eecAve pressure loss in
the secAon.

Pressure Loss CalculaAons for

Bit Nozzles and Hydraulic
OpAmizaAon

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Flow through Nozzles

Velocity through nozzle:

!! =

!
!
3.117!!

Energy balance equaAon:

Combining and solving for pressure:

!! 8.07410!! !!!! = !! !

!! =

Solving energy balance for velocity,

introducing discharge coecient:

!! = !!

8.31110!! !!!
!
!!! !!!

!!
!!
8.07410!! !

vn
= Nozzle velocity (j/sec)
At
= Total ow area (in2)
q
= Flow rate (gpm)
Pb = Pressure drop at nozzle (psi)

= Fluid density (ppg)
Cd
= Discharge coefficient, as high as 0.98, more practical 0.95
Dnozzle = Nozzle size in multiplies of 1/32 inch

Bit nozzle diameters are ojen expressed in

32nds of an inch. For example, if the bit
nozzles are described as 12-13-13 this
denotes that the bit contains one nozzle
12/32 and two nozzles having a diameter of
13/32 in.

Bit Performance OpAmizaAon

Bit hydraulic horsepower:

!!"!"# =

!!"# !
!
1714

Bit performance - bit hydraulic horsepower/in2:
Bit!Performance!

!!"!"#

!"#

!!"
= ! !"#
!
2
!
!"#
4

Bit performance should be between 2 - 5.5!

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

OpAmizaAon of Jet Impact Force

Jet impact force:

!! = 0.01823!! ! !!! !

Studies show that cross ow beneath the face of the bit is

the most eecAve parameter in hole cleaning. Cross ow is
a maximum when impact force is maximum.

Bit pressure loss:

8.31110!! !!!
!! =
!
!!! !!!
Nominal HHP pump
!
!
!!"!!!" > !"!#$ !
1714
As the uid velocity (and rate) increases, all
pressure drop values in the system increase
(assume constant nozzle size). There comes a
point where the nominal HHP of the pump would
be exceeded. The only way to increase uid
velocity further is to increase the nozzle size to
decrease the pressure drop at the bit. In return, jet
impact force would decrease.

Simple Hydraulics OpAmizaAon

Calculate minimum required ow rate (q) based on a minimum annular
velocity (120 A/min) to transport curngs in the secAon with the largest
cross secAonal area (depends on well construcAon and DP OD).
Calculate pressure losses in all surface, pipe and annular secAons for
calculated ow rate as discussed.
Calculate pressure losses across bit nozzles, hydraulic horse power at the
bit, bit performance and hydraulic horsepower requirements for the total
circulaAon system.
Calculate ECD along the open hole secAon.
Three requirements must now be fullled (note that minimum annular
velocity is already fullled):
1. Bit performance must be between 2 - 5.5
2. Total hydraulic horsepower requirements must go conrm with selected pump
3. ECD must always be below formaAon fracture gradient

If one of above is not fullled, change bit nozzle sizes. Increase viscosity of
mud to reduce minimum annular velocity requirements.

Chair of Drilling Engineering - University Leoben

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PE DESIGN, PART A - DRILLING ENGINEERING: Mud Hydraulics

Summary of FricAon Pressure Loss

EquaAons (1/2)

Summary of FricAon Pressure Loss

EquaAons (2/2)

Chair of Drilling Engineering - University Leoben

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